Method for bending a vinyl floor plank to form a stair nose plank

ABSTRACT

A method for bending a vinyl floor plank to form a stair nose plank. A first bending gap is established between two blending blocks and a second bend gap is established between two second bending blocks. Heat is applied to a vinyl floor plank along a first bend location. The vinyl floor plank is then placed into the first bend gap. A user presses downward on the vinyl floor plank to form a first right angle bend. Heat is applied to a vinyl floor plank along a second bend location. The vinyl floor plank is then placed into the second bend gap. The user presses downward on the vinyl floor plank to form a second right angle bend. The first right angle bend and the second right angle bend combine to form a U-shaped bend to form a stair nose plank. In a preferred embodiment the stair nose plank includes a locking mechanism along its edges. In a preferred embodiment heat is applied by utilization of an acrylic bending machine.

BACKGROUND OF THE INVENTION

Vinyl plank flooring is known in the prior art. FIG. 1 shows a top viewof vinyl flooring plank 1. Popular vinyl planks include luxury vinyltile flooring (LVT), luxury vinyl plank flooring (LVP), stone plasticcomposite vinyl flooring (SPC), and other acrylic or vinyl typefloorings. Vinyl planks varies in size, with most widths ranging from 6inches up to 7¾ inches but varying between 5 inches and 8 inches andtypical lengths ranging from 36 to 48 inches. Vinyl planks range inthickness from 2 mm for lower quality products to 8 mm or more forhigher quality products. This measurement varies since luxury vinyl tileis comprised of four-to-five different distinct layers that include aurethane coating, the wear layer, a print film layer, the vinyl core,and the backing. Vinyl planks typically include locking mechanism 2 thatsurrounds the planks and is for click locking adjacent planks together.FIG. 2 shows tongue 3 and groove 4 of locking mechanism 2.

Acrylic bending machines are known in the prior art. FIG. 3 showsacrylic bending machine 5. Acrylic bending machine 5 (model no.ABM700/1300) is available from Aecfun Commercial Equipment Co., Ltd ofJiaxing, China. Acrylic bending machine 5 is a useful tool for softeningand bending acrylic, organic glass, plexiglass, and polyvinyl chloride(PVC) into shapes. Acrylic bending machine 5 may be used for signmaking, display cases, artware making, and other applications. Acrylicbending machine 5 uses an infrared tube (not shown) for heating. Thetemperature is adjustable according to the different thickness of theplastic sheet being bent with a maximum temperature of 600° C. Acrylicbending machine 5 includes an adjustable heating gap 6 where the gapwidth is adjustable between 0-20 mm, according to the needs of the user.The horizontal position of the plastic sheet being bent over heating gap6 is adjustable by manipulating adjustable arm 50.

Vinyl plank flooring is very popular. Unfortunately, however, prior artstair nose pieces must be specially ordered, are expensive, difficult towork with and do not include locking mechanisms for click locking thestair nose plank to other vinyl planks.

What is needed is an improved method for fabricating vinyl plank stairnose pieces.

SUMMARY OF THE INVENTION

The present invention provides a method for bending a vinyl floor plankto form a stair nose plank. A first bending gap is established betweentwo blending blocks and a second bend gap is established between twosecond bending blocks. Heat is applied to a vinyl floor plank along afirst bend location. The vinyl floor plank is then placed into the firstbend gap. A user presses downward on the vinyl floor plank to form afirst right angle bend. Heat is applied to a vinyl floor plank along asecond bend location. The vinyl floor plank is then placed into thesecond bend gap. The user presses downward on the vinyl floor plank toform a second right angle bend. The first right angle bend and thesecond right angle bend combine to form a U-shaped bend to form a stairnose plank. In a preferred embodiment the stair nose plank includes alocking mechanism along its edges. In a preferred embodiment heat isapplied by utilization of an acrylic bending machine.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-2 show a prior art vinyl floor plank.

FIG. 3 shows a prior art acrylic bending machine.

FIGS. 4-14 show a preferred method for bending a vinyl flooring plank toform a stair nose plank.

FIG. 15 shows a perspective view of a preferred stair nose plank.

FIG. 16 shows preferred stair nose planks installed on steps.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Utilization of thePreferred Embodiments

FIG. 4 shows a top view of acrylic bending machine 5 positioned on thetop of table 10. First bending blocks 11 and 12 are bolted via bolts 30to table 10 as shown. Second bending blocks 14 and 15 are likewisebolted via bolts 30 to table 10. Bending blocks 11 and 12 are separatedby bending gap 20 and bending blocks 14 and 15 are separated by bendinggap 22.

In FIG. 5 , user has placed spacer block 40 and spacer block 41 next toadjustable support arm 50. Spacer blocks 40 and 41 and support arm 50function to properly horizontally position a flooring plank over heatinggap 6. In one preferred embodiment, heating gap 6 has been adjusted sothat the gap measures approximately 10 mm. Also, in one preferredembodiment the heating tube has been adjusted so that the heat appliedthrough heating gap 6 is approximately 425° C.

In FIGS. 6-8 , the user has placed plank 1 against over heating gap 6and adjacent to spacer block 41. Plank 1 is a vinyl plank having athickness of approximately 5 mm. In a preferred embodiment, the userholds plank 1 over heating gap 6 for approximately 50 seconds.

In FIG. 9 , the user has placed plank 1 in bending gap 20 so that heatedarea 1B is located near the top of bending blocks 12 and 11.

In FIGS. 10 and 11 , the user has pressed down on plank 1 as shown sothat first right angle bend 100 is formed in plank 1. The user holdsplank 1 down in the position shown in FIGS. 10 and 11 for approximately50 seconds while bend 100 cools to hold rigid its shape at the rightangle.

In FIG. 12 , the user has placed bent plank 1 over heat gap 6 as shownto heat plank 1 at location 1C. In a preferred embodiment, the userholds plank 1 over heating gap 6 for approximately 50 seconds.

In FIG. 13 , the user has placed plank 1 in bending gap 20 so thatheated area 1C is located near the top of bending blocks 15 and 14.

In FIG. 14 , the user has pressed down on plank 1 as shown so thatsecond right angle bend 150 is formed, thereby forming bent plank 1D.The user holds plank 1D down in the position shown in FIG. 14 forapproximately 50 seconds while bend 150 cools to hold rigid its shape atthe right angle.

FIG. 15 shows a perspective view of bent plank 1D having U-shaped bend200 to form a stair nose piece. It should be noted that plank 1Dincludes locking mechanism 2 for easy, efficient and secureinstallation. For example, FIG. 16 shows multiple stair nose planks 1Dinstalled on stairs and locked to non-bent planks 1.

Although the above-preferred embodiments have been described withspecificity, persons skilled in this art will recognize that manychanges to the specific embodiments disclosed above could be madewithout departing from the spirit of the invention. Therefore, theattached claims and their legal equivalents should determine the scopeof the invention.

What is claimed is:
 1. A method for bending a vinyl floor plank to forma bent stair nose plank, said method comprising the steps of: A.establishing a first bend gap between two first bending blocks, B.establishing a second bend gap between two second bending blocks, C.applying heat to a vinyl floor plank along a first bend location, D.placing said vinyl floor plank into said first bend gap, E. pressingdownward on said vinyl floor plank to form a first right angle bend, F.applying heat to a vinyl floor plank along a second bend location, G.placing said vinyl floor plank into said second bend gap, H. pressingdownward on said vinyl floor plank to form a second right angle bend,wherein said first right angle bend and said second right angle bendcombine to form a U-shaped bend to form said stair nose plank.
 2. Themethod as in claim 1, wherein said heat is applied to said vinyl floorplank by utilization of an acrylic bending machine.
 3. The method as inclaim 1, wherein said two first bending blocks are rigidly attached to atable.
 4. The method as in claim 1, wherein said two second bendingblocks are rigidly attached to a table.
 5. The method as in claim 1,wherein said stair nose plank comprises a locking mechanism along theedge of said stair nose plank.